Case Study: Cascades achieves successful market expansion with Valmet grade conversion rebuild

Cascades doubles Bear Island mill capacity with Valmet

Cascades, a packaging company, faced the challenge of expanding its market presence in the southeastern U.S. by converting an old newsprint machine at its Bear Island mill to produce lightweight, 100% recycled containerboard. They selected Valmet as their partner for this strategic grade conversion rebuild due to Valmet's expertise with similar projects and their role as the original equipment manufacturer for the existing machine.

Valmet implemented a comprehensive rebuild, supplying key technologies including a new OptiFlo Gap headbox, an OptiSizer Film sizer, and an OptiWin Drum winder, supported by a Performance Agreement for ongoing optimization. The solution doubled the mill's capacity to 465,000 short tons annually. The start-up was exceptionally successful, with quality targets met within weeks, and the mill achieved top-quartile performance for water and energy consumption, making it highly efficient and sustainable.

Cascades